The EIP Protocol Converter System is a system that facilitates integration of laser or dot peer marking systems into factory automation networks using the standard EtherNet/lP (EIP) protocol. Built-in support for the EIP protocol greatly simplifies the PLC programming task, and lowers the cost of integrating the marking system into factory operations.
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1. An EtherNet/IP Industrial Protocol (EIP) protocol converter system that enables programmable logic controller (PLC) control of marking systems comprising: a marking controller comprising a marking system utilized by a specific manufacturer; a PLC generating an object model the object model being a compound data structure representing a virtual marking system corresponding to the marking system of the marking controller; the object model comprised of information expressed as a table incorporating tags, the tags representing values corresponding to functions that are recognized by the marking controller; said functions comprising commands, marking data, and setpoints; an EIP controller receiving the object model as an EIP packet sent from the PLC via an Ethernet data link; the EIP controller exposing the object model in the EIP protocol, extracting the information, executing one or more finite state machine programs whereby the information is translated into a sequence of proprietary API commands that is recognized by the marking controller, communicating the proprietary API commands to the marking controller, which is in constant loop communication with the one or more finite state machines, thereby supervising the functions of the marking controller to complete a marking job.
This invention relates to an EtherNet/IP Industrial Protocol (EIP) protocol converter system designed to enable programmable logic controller (PLC) control of marking systems. The system addresses the challenge of integrating PLCs with proprietary marking systems from different manufacturers, which typically require specific communication protocols and command structures. The system includes a marking controller that operates a manufacturer-specific marking system. A PLC generates an object model, a compound data structure representing a virtual version of the marking system. This object model contains information organized as a table with tags, where each tag corresponds to a function recognized by the marking controller, such as commands, marking data, or setpoints. The PLC sends this object model as an EIP packet over an Ethernet data link to an EIP controller. The EIP controller processes the object model, exposing it in the EIP protocol and extracting the embedded information. It then executes one or more finite state machine programs to translate the information into proprietary API commands compatible with the marking controller. These commands are sent to the marking controller, which maintains continuous communication with the finite state machines. This loop ensures real-time supervision of the marking controller's functions, allowing it to complete marking jobs as directed by the PLC. The system effectively bridges the gap between standard industrial protocols and proprietary marking systems, enabling seamless integration and control.
2. The system of claim 1 wherein a PLC generating an object model is accomplished by a PLC program writing desired values into the table incorporating tags.
A system for industrial automation involves a programmable logic controller (PLC) that generates an object model by writing desired values into a table incorporating tags. The PLC executes a program to create and manage this object model, which represents data structures and relationships in a standardized format. The object model facilitates communication and data exchange between the PLC and other devices or systems, such as human-machine interfaces (HMIs), supervisory control and data acquisition (SCADA) systems, or enterprise resource planning (ERP) systems. The tags within the table serve as identifiers for variables, parameters, or data points, enabling structured access and manipulation of the object model. This approach improves interoperability, simplifies integration, and enhances data consistency across different automation components. The system may also include additional features, such as real-time monitoring, data logging, or remote configuration, to support various industrial applications. The use of a PLC-generated object model reduces the need for manual configuration, minimizes errors, and streamlines the deployment of automation solutions.
3. The system of claim 1 wherein supervising the functions of the marking controller to complete a marking job is performed using only two EIP commands: Load Job File, and Prepare, and Mark Job.
Technical Summary: This invention relates to a system for supervising and controlling a marking controller in a marking job process. The system addresses the need for a simplified and efficient method of managing marking operations, reducing complexity and potential errors in command execution. The system supervises the marking controller using only three essential EIP (Ethernet/IP) commands: Load Job File, Prepare, and Mark Job. The Load Job File command transfers the necessary job data to the marking controller, ensuring all required parameters and instructions are available for execution. The Prepare command initializes the marking controller, setting up the system for the upcoming job by configuring hardware and software settings. The Mark Job command executes the actual marking operation, directing the controller to perform the specified tasks based on the loaded job file. By limiting the supervisory process to these three commands, the system streamlines the workflow, minimizes communication overhead, and reduces the risk of errors associated with more complex command sequences. This approach enhances reliability and efficiency in marking operations, making it particularly suitable for industrial applications where precision and speed are critical. The system ensures that the marking controller operates within predefined parameters, completing the job accurately and consistently.
4. The system of claim 1 wherein the marking controller is a dot peen marking controller.
A dot peen marking system is used for permanently marking surfaces, such as metal parts, with alphanumeric characters, symbols, or other identifiers. The system includes a marking controller that directs a marking tool to create precise indentations on the surface, forming the desired markings. In this specific configuration, the marking controller is a dot peen controller, which operates by rapidly striking the surface with a hardened pin to create small dots or indentations. The controller regulates the pin's movement, ensuring consistent dot spacing, depth, and alignment to form clear and durable markings. The system may also include a positioning mechanism to align the marking tool with the target surface, a power supply to drive the marking process, and a user interface for inputting or selecting the desired markings. The dot peen marking method is particularly useful in industrial applications where permanent, high-contrast markings are required, such as part identification, serial numbering, or quality control. The system ensures precision and reliability, even on rough or textured surfaces, by controlling the marking depth and dot formation. This configuration enhances durability and readability of the markings, making it suitable for harsh environments where other marking methods may fail.
5. The system of claim 1 wherein the marking controller is a laser marking controller.
A laser marking system is used to apply precise, durable markings on various materials, such as metals, plastics, or ceramics, for identification, traceability, or decorative purposes. Traditional marking methods, such as inkjet or mechanical engraving, may lack precision, durability, or flexibility in adapting to different materials and marking requirements. Laser marking offers high precision, speed, and versatility but requires precise control to ensure consistent and high-quality results. The system includes a laser marking controller that regulates the laser's power, pulse duration, and movement to create the desired markings. The controller adjusts these parameters in real-time to account for variations in material properties, ensuring consistent marking quality. The system may also include a positioning mechanism to align the laser beam accurately with the target surface. The laser marking controller may interface with a computer or automated system to receive marking instructions, such as text, barcodes, or logos, and convert them into precise laser control commands. This ensures that the markings are applied with the required precision and durability, meeting industrial or regulatory standards. The system is particularly useful in manufacturing, aerospace, medical device production, and other industries where traceability and quality control are critical.
6. The system of claim 5 further comprised of an Ethernet switch which routes the object model from the PLC to the EIP controller and which communicates the proprietary API commands from the EIP controller to the laser marking controller.
This invention relates to an industrial automation system for laser marking, addressing the challenge of integrating proprietary communication protocols between different control devices. The system includes a programmable logic controller (PLC) that generates an object model representing data for laser marking operations. An Ethernet switch routes this object model to an EtherNet/IP (EIP) controller, which translates the data into proprietary API commands. These commands are then transmitted to a laser marking controller, enabling precise control of the laser marking process. The Ethernet switch ensures seamless communication between the PLC and the EIP controller, while the EIP controller acts as an intermediary, converting standard industrial protocol data into the specific commands required by the laser marking system. This integration allows for efficient and accurate laser marking operations within an industrial automation environment, overcoming compatibility issues between different control systems. The system enhances flexibility and interoperability in manufacturing processes by bridging disparate communication protocols.
7. The system of claim 1 further comprised of a vision system that calculates a mark quality grade.
A system for evaluating printed marks, such as barcodes or other machine-readable symbols, includes a vision system that captures images of the marks and analyzes their quality. The system determines a mark quality grade by assessing factors such as contrast, resolution, and structural integrity. This evaluation helps identify defects or deviations from standards, ensuring the marks remain readable by scanning devices. The vision system may use image processing techniques, such as edge detection or pattern recognition, to quantify the mark's quality. The system may also compare the captured image against a reference template to detect inconsistencies. The quality grade can be used to trigger corrective actions, such as reprinting or adjusting printing parameters, to maintain compliance with readability requirements. The system is particularly useful in manufacturing, logistics, and packaging applications where accurate mark recognition is critical. By automating quality assessment, the system reduces manual inspection errors and improves efficiency in production lines.
8. The system of claim 7 wherein the EIP controller receives data from the vision system and compares the data from the vision system to the marking data received from object model, if the data from the vision system and the marking data received from object model are equal then the marking job is complete, if the data from the vision system is a lower quality grade than the marking data received from object mode l then the marking job is repeated.
This invention relates to a quality control system for marking objects, particularly in automated manufacturing or assembly processes. The system addresses the challenge of ensuring accurate and consistent marking on objects by verifying the quality of applied markings using a vision system and an object model. The system includes an EIP (Ethernet Industrial Protocol) controller that interfaces with a vision system and an object model database. The vision system captures images of marked objects, while the object model provides reference marking data for comparison. The EIP controller processes this data to determine if the marking job meets quality standards. If the vision system data matches the reference marking data, the marking job is deemed complete. If the vision system detects a lower-quality marking (e.g., incomplete, misaligned, or faded), the system triggers a repeat of the marking process to ensure accuracy. This closed-loop verification improves production efficiency by reducing defects and minimizing manual inspection. The system is particularly useful in high-precision applications where marking consistency is critical, such as in electronics, automotive, or medical device manufacturing.
9. The system of claim 1 wherein the EIP controller executes a concatenation function, the concatenation function comprising receiving the marking data in discrete blocks as field strings, caching and indexing the field strings, collecting the field strings and appending the field strings together in a large concatenation buffer memory forming a larger single text string.
This invention relates to data processing systems for handling and manipulating marking data, particularly in environments where data is received in discrete blocks. The system addresses the challenge of efficiently processing and combining fragmented data fields into a coherent, larger text string for further analysis or storage. The system includes an EIP (Enterprise Information Processing) controller that performs a concatenation function. This function involves receiving marking data in discrete blocks, where each block is structured as a field string. The controller caches and indexes these field strings to manage and track the incoming data. The field strings are then collected and sequentially appended together in a large concatenation buffer memory, forming a single, larger text string. This process ensures that fragmented data blocks are accurately combined without loss or corruption, enabling seamless integration of the data for subsequent processing tasks. The concatenation function optimizes memory usage by dynamically managing the buffer size and efficiently handling the appending operations. This approach is particularly useful in applications requiring real-time data aggregation, such as document processing, log file analysis, or database management, where maintaining data integrity and coherence is critical. The system enhances data processing efficiency by reducing the overhead associated with handling discrete data blocks individually.
10. The system of claim 1 , wherein the EIP controller executes a duplication prevention function, the duplication prevention function comprising comparing newly received marking data to previously received marking data, if the newly received marking data and the previously received marking data are equal a duplication fault is raised and the marking job is prevented, if the newly received marking data and the previously received marking data are not equal, the newly received marking data is stored for subsequent comparison and the marking job is allowed to proceed.
A system for preventing duplicate marking operations in a marking device includes an EIP (Embedded Image Processing) controller that executes a duplication prevention function. The function compares newly received marking data to previously stored marking data. If the newly received data matches the previously stored data, a duplication fault is raised, and the marking job is halted to prevent redundant or unintended operations. If the data does not match, the new data is stored for future comparisons, and the marking job proceeds. This ensures that identical marking operations are not performed consecutively, reducing waste and errors in marking processes. The system may also include a marking device interface for receiving marking commands and a storage module for retaining previously received marking data. The EIP controller processes the marking data, executes the duplication check, and controls the marking device based on the comparison result. This prevents accidental or unintended repetition of marking tasks, improving efficiency and accuracy in automated marking systems.
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March 13, 2018
January 28, 2020
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